Spacer Textile Material With Tensile Strands In Non-Linear Arrangements

ABSTRACT

A spacer textile material has at least a portion of a tensile strand located between a first layer and a second layer of the spacer textile material where the first layer and second layer have been joined together to form channels in which the tensile strand moves freely. The tensile strand travels through the spacer textile material in a non-linear direction. Further, the channels may be formed in the spacer textile material in non-linear directions. The spacer textile material with a tensile strand may be incorporated into an article of footwear.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of Beye et al., U.S. Pat. No. ______,U.S. Patent Publication Number 2014/0196310, now U.S. patent applicationSer. No. 13/741,433, filed Jan. 15, 2013, and titled “Spacer TextileMaterial With Tensile Strands in Non-Linear Arrangements,” the entiretyof which is herein incorporated by reference.

RELATED APPLICATIONS

This application is related the following commonly owned co-pendingapplications: Follett, U.S. Pat. No. 9,095,186, issued Aug. 4, 2015, andtitled “Article of Footwear Incorporating Braided Tensile Strands”; Beyeet al., U.S. Pat. No. 9,132,601, issued Sep. 15, 2015, and titled“Spacer Textile Material with Tensile Strands Having Multiple Entry andExit Points”; Beye et al., U.S. Pat. No. 9,241,537, issued Jan. 26,2016, and titled “Spacer Textile Material With Tensile Strands thatIntersect”; and Follett et al., U.S. Pat. No. 9,226,548, issued Jan. 5,2016, and titled “Spacer Textile Material With Channels Having MultipleTensile Strands,” which are all incorporated by reference herein intheir entireties.

BACKGROUND

Articles of footwear generally include two primary elements: an upperand a sole structure. The upper is often formed from a plurality ofmaterial elements (e.g., textiles, polymer sheet layers, foam layers,leather, synthetic leather) that are stitched or adhesively bondedtogether to form a void on the interior of the footwear for comfortablyand securely receiving a foot. More particularly, the upper forms astructure that extends over instep and toe areas of the foot, alongmedial and lateral sides of the foot, and around a heel area of thefoot. The upper may also incorporate a lacing system to adjust the fitof the footwear, as well as permitting entry and removal of the footfrom the void within the upper. In addition, the upper may include atongue that extends under the lacing system to enhance adjustability andcomfort of the footwear, and the upper may incorporate a heel counter.

The various material elements forming the upper impart specificproperties to different areas of the upper. For example, textileelements may provide breathability and may absorb moisture from thefoot, foam layers may compress to impart comfort, and leather may impartdurability and wear-resistance. As the number of material elementsincreases, the overall mass of the footwear may increase proportionally.The time and expense associated with transporting, stocking, cutting,and joining the material elements may also increase. Additionally, wastematerial from cutting and stitching processes may accumulate to agreater degree as the number of material elements incorporated into anupper increase. Moreover, products with a greater number of materialelements may be more difficult to recycle than products formed fromfewer material elements. By decreasing the number of material elements,therefore, the mass of the footwear and waste may be decreased, whileincreasing manufacturing efficiency and recyclability.

The sole structure is secured to a lower portion of the upper so as tobe positioned between the foot and the ground. In athletic footwear, forexample, the sole structure includes a midsole and an outsole. Themidsole may be formed from a polymer foam material that attenuatesground reaction forces (i.e., provides cushioning) during walking,running, and other ambulatory activities. The midsole may also includefluid-filled chambers, plates, moderators, or other elements thatfurther attenuate forces, enhance stability, or influence the motions ofthe foot, for example. The outsole forms a ground-contacting element ofthe footwear and is usually fashioned from a durable and wear-resistantrubber material that includes texturing to impart traction. The solestructure may also include a sockliner positioned within the upper andproximal a lower surface of the foot to enhance footwear comfort.

SUMMARY

In one aspect, a spacer textile material includes a first layer, asecond layer and a plurality of connecting members extending between andjoining the first layer and the second layer. The spacer textilematerial also includes a tensile strand, where a first portion of thetensile strand and a second portion of the tensile strand are disposedbetween the first layer and second layer. The spacer textile materialalso includes a first channel and a second channel bounded by portionsof the first layer and the second layer that are in direct contact. Thefirst portion of the tensile strand is disposed within the first channeland the second portion of the tensile strand is disposed within thesecond channel. The first channel and the second channel are arranged ina non-linear pattern.

In another aspect, a spacer textile material includes a first layer, asecond layer and a plurality of connecting members extending between andjoining the first layer and the second layer. The spacer textilematerial also includes a tensile strand. The first layer is joined tothe second layer to define a plurality of channels arranged in anon-linear pattern and the tensile strand extends through the pluralityof channels.

In another aspect, an article of footwear includes an upper and a solestructure, where at least a portion of the upper comprises: a firstlayer, a second layer, a plurality of connecting members extendingbetween and joining the first layer and the second layer and a tensilestrand. The first layer is joined to the second layer along a pluralityof welds and where the plurality of welds define a plurality of channelsarranged in a non-linear pattern. The tensile strand is disposed withinthe plurality of channels.

Other systems, methods, features and advantages of the disclosure willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the disclosure, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the disclosure. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 shows an embodiment of the spacer textile material;

FIG. 2 shows an embodiment of the spacer textile material having atensile strand disposed between a first layer and a second layer;

FIG. 3 is a schematic diagram of an embodiment of the spacer textilematerial having a tensile strand in a welding device prior to thejoining of the first layer and second layer;

FIG. 4 is a schematic diagram of an embodiment of a welding deviceduring the joining of the first layer and second layer of a spacertextile material having a tensile strand disposed between a first layerand a second layer;

FIG. 5 is a schematic diagram of an embodiment of the spacer textilematerial having a tensile strand disposed in channels defined by one ormore welds created by a welding method;

FIG. 6 is a schematic diagram of an embodiment of the spacer textilematerial having a tensile strand where the tensile strand is locatedthrough the spacer textile material in a non-linear pattern;

FIG. 7 is a schematic diagram of an embodiment of the spacer textilematerial having a tensile strand where the tensile strand is locatedthrough the spacer textile material in a non-linear pattern;

FIG. 8 is a schematic diagram of an embodiment of the spacer textilematerial having a tensile strand where the tensile strand is locatedthrough the spacer textile material in a non-linear pattern;

FIG. 9 is a schematic diagram of an embodiment of the spacer textilematerial having a tensile strand where the tensile strand is locatedthrough the spacer textile material in a non-linear pattern;

FIG. 10 is a schematic diagram of an embodiment of the spacer textilematerial having two tensile strands where the tensile strands arelocated about the spacer textile material in multiple non-linearpatterns; and

FIG. 11 is a schematic diagram of an embodiment of an article offootwear incorporating a spacer textile material having tensile strandsarranged in a non-linear pattern as a portion of the upper of thearticle of footwear.

DETAILED DESCRIPTION

FIG. 1 illustrates an embodiment of a spacer textile material 100. Inone embodiment, spacer textile material 100 may include a first layer110, as well as a second layer 120 that is at least partiallycoextensive with first layer 110. In addition, spacer textile material100 may have a plurality of connecting members 130 that extend betweenand join first layer 110 and second layer 120.

Connecting members 130 may be arranged to form a series of rows. Therows of connecting members 130 are separated by various spaces. In someembodiments, the rows formed by connecting members 130 may besubstantially parallel to each other and distributed at substantiallyequal distances across spacer textile material 100. In otherembodiments, the rows could be non-parallel and/or unevenly spacedapart. Spaces may be areas within spacer textile material 100 whereconnecting members 130 are absent. Typically, spaces may include areasbetween the rows formed by connecting members 130.

Spacer textile material 100 also may define at least a pair of oppositeedges, first edge 140 and second edge 160, which are also edges of firstlayer 110 and second layer 120. In some embodiments, each of first edge140 and second edge 160 may be substantially parallel to the rows formedby connecting members 130.

The spacer textile material may be formed by any suitable method formanufacturing such a material. A general process may include one or moreyarns being fed into a conventional knitting apparatus. The knittingapparatus may mechanically manipulate yarns to form each of a firstlayer and a second layer. The knitting apparatus may also manipulateyarns to form connecting members between the first and second layers. Assuch, the first layer and second layer may be knitted layers, and theconnecting members may be sections of at least one yarn that extendbetween the first layer and second layer. Moreover, the process formsspaces, edges, and stabilization structures.

Once formed, the spacer textile material exits the knitting apparatusand is collected on a roll. After a sufficient length of spacer textilematerial is collected, the roll may be shipped or otherwise transportedto a manufacturer to utilize the spacer textile material for themanufacture of footwear or for any other purposes. Although not alwaysperformed, the spacer textile material may be subjected to variousfinishing operations (e.g., dying, fleecing) prior to being collected ona roll.

Examples of spacer textile material and methods of making spacer textilematerial are disclosed in any of the following: Hazenberg et al., U.S.Pat. No. 9,375,049, entitled, “Spacer Textile Materials and Methods forManufacturing the Spacer Textile Materials,” issued on Jun. 28, 2016;Goodwin et al., U.S. Pat. No. 6,119,371, entitled “Resilient Bladder forUse in Footwear,” issued on Sep. 19, 2000; and Goodwin, U.S. Pat. No.7,076,891, entitled “Flexible Fluid-Filled Bladder for an Article ofFootwear,” issued on Jul. 18, 2006, the entirety of each beingincorporated by reference.

Some embodiments of a spacer textile material may include a tensilestrand. In some embodiments, one or more portions of the tensile strandmay be located between the first layer and the second layer. In someembodiments, one or more portions of the tensile strand may be disposedin channels that may be created by joining a first layer and secondlayer of the spacer textile material. After assembly, the tensile strandmay move freely within the one or more channels.

As discussed above, the spacer textile material may include at least onetensile strand. The tensile strand may be located in any portion of thespacer textile material. FIG. 2 shows an embodiment of a spacer textilematerial 200. Spacer textile material 200 may include tensile strand240. Further, spacer textile material 200 may include a plurality ofconnecting members 230 that extend between and join first layer 210 andsecond layer 220. Connecting members 230 may be arranged to form aseries of rows that are separated by various spaces. A portion oftensile strand 240 may be disposed between first layer 210 and secondlayer 220. In particular, tensile strand 240 may be disposed in thespace created between connecting members 230.

Spacer textile material 200 also defines at least a pair of oppositeedges, first edge 250 and second edge 260. First edge 250 and secondedge 260 also may be edges of first layer 210 and second layer 220. Insome embodiments, each of first edge 250 and second edge 260 may besubstantially parallel to the rows formed by connecting members 230.However, in other embodiment, first edge 250 and/or second edge 260 maynot be parallel with the rows formed by connecting members 230.

In different embodiments, the arrangement of a tensile strand within aspacer textile material can vary. For example, various portions of atensile strand may extend through spacer textile material (i.e., betweena first layer and a second layer) in parallel with, or at various anglesto, one or more edges of the spacer textile material. Additionally, insome embodiments, different portions or segments of a tensile strand maybe aligned in parallel with one another. In other embodiments, differentportions or segments of a tensile strand could be disposed at variousangles to one another.

An exemplary arrangement of a tensile strand within a spacer textilematerial is shown in FIG. 2. In the embodiment shown in FIG. 2, a firstportion 241 of tensile strand 240 may be disposed between first layer210 and second layer 220 of spacer textile material 200. Moreover, firstportion 241 may generally extend from first edge 250 to second edge 260.In addition, a third portion 243 of tensile strand 240 may also bedisposed between first layer 210 and second layer 220 of spacer textilematerial 200 and may likewise extend between first edge 250 and secondedge 260. Furthermore, a second portion 242 of tensile strand 240 may bedisposed between first portion 241 and third portion 243. In contrast tofirst portion 241 and third portion 243, which may be disposed betweenadjacent layers of spacer textile material 200, second portion 242 mayextend outwardly from second edge 260 such that second portion 242 isnot disposed between first layer 210 and second layer 220. In someembodiments, second portion 242 forms a loop that extends from secondedge 260 of spacer textile material 200.

As one exemplary arrangement, first portion 241 and third portion 243are shown extending in parallel between first edge 250 and second edge260. Moreover, first portion 241 and third portion 243 may be orientedin a direction that is approximately perpendicular to first edge 250 andsecond edge 260. However, as previously discussed, in other embodimentsone or more portions could vary in their orientations relative to otherportions of a tensile strand and/or could vary in their orientationsrelative to edges of a spacer textile material.

The tensile strands of the disclosure may be formed from any generallyone-dimensional material. As utilized with respect to the presentdisclosure, the term “one-dimensional material” or variants thereof isintended to encompass generally elongate materials exhibiting a lengththat is substantially greater than a width and a thickness.

The tensile strands of the disclosure may be formed from any suitablematerial. Accordingly, suitable materials for a tensile strand, forexample tensile strand 240 of FIG. 2, may include various filaments,fibers, yarns, threads, cables, cords, or ropes. Suitable material for atensile strand may be formed from or include rayon, nylon, polyester,polyacrylic, silk, cotton, carbon, glass, aramids (e.g., para-aramidfibers and meta-aramid fibers), ultra high molecular weightpolyethylene, liquid crystal polymer, copper, aluminum, steel, andvarious combination of these kinds of materials.

Filaments have an indefinite length and in some cases a single filamentcan be utilized as a tensile strand, such as tensile strand 240. Fibershave a relatively short length and generally go through spinning ortwisting processes to produce a strand of suitable length. An individualfilament utilized in a tensile strand may be formed from a singlematerial (i.e., a monocomponent filament) or from multiple materials(i.e., a bicomponent filament). Similarly, different filaments may beformed from different materials. As an example, yarns utilized astensile strand 240 may include filaments that may be formed from acommon material, or may include filaments that may be formed from two ormore different materials. Similar concepts also apply to threads,cables, or ropes.

The spacer textile material of the disclosure may include two or moretensile strands. In some embodiments, when the spacer textile materialincludes multiple tensile strands, the tensile strands may be made fromthe same material. In some embodiments, the tensile strands may be madefrom different materials. When the tensile strands are made fromdifferent materials, the tensile strands may include differentcharacteristics. For example, a first tensile strand may stretch when aforce is applied. In some embodiments, a second tensile strand maystretch less than first tensile strand. In other embodiments, a secondtensile strand may stretch more than the first tensile strand.

In some embodiments, the thickness of tensile strands may also varysignificantly to range from less than 0.03 millimeters to more than 5millimeters, for example. Although one-dimensional materials will oftenhave a cross-section where the width and the thickness are substantiallyequal (e.g., a round or square cross-section), some one-dimensionalmaterials may have a width that is greater than a thickness (e.g., arectangular, oval, or otherwise elongate cross-section). Despite thegreater width, a material may be considered one-dimensional if thelength of the material is substantially greater than the width and thethickness of the material.

In some embodiments having multiple tensile strands, the thickness ofeach strand may be the same. In other embodiments, the thickness of eachtensile strand may be different. The relative thickness of two or moretensile strands may be selected according to various factors includingdesired strength, elasticity, manufacturing considerations as well aspossible other factors.

Examples of suitable tensile strands are disclosed in any of thefollowing: Dojan et al., U.S. Pat. No. 8,925,129, entitled, “Methods ofManufacturing Articles of Footwear With Tensile Strand Elements,” issuedon Jan. 6, 2015; Dojan et al., U.S. Pat. No. 8,819,963, entitled,“Articles of Footwear With Tensile Strand Elements,” issued on Sep. 2,2014; and Dojan et al., U.S. Pat. No. 8,973,288, entitled “FootwearIncorporating Angled Tensile Strand Elements,” issued on Mar. 10, 2015,the entirety of each being hereby incorporated by reference.

A tensile strand can be configured in any pattern, configuration orarrangement in a spacer textile material. In some embodiments, a tensilestrand can be confined to a particular region of a spacer textilematerial. In other embodiments, a tensile strand may be associated withmultiple different regions of a spacer textile material, including theentirety of the spacer textile material. Moreover, a tensile strand canextend through a spacer textile material (i.e., between adjacentlayers), as well as outside of the layers that form the spacer textilematerial. In some embodiments, portions of a tensile strand may extendalong an outer surface or outer face of a layer. In still otherembodiments, portions of a tensile strand could extend along an edge ofa spacer textile material.

For purposes of this disclosure, the term “opening” may include a spacealong an edge of the spacer textile material between a first layer and asecond layer that is also between connecting members of the spacertextile material. Further, the term “opening” may include a spacebetween the knitted strands of the first layer or second layer of thespacer textile. Further, the term “opening” may include a space, slit orhole in the first layer or second layer created during the preparationof the spacer textile material. As stated above, the tensile strand maybe disposed through any opening on the spacer textile material.

The figures of this disclosure may show the ends of each tensile strandextending beyond the edges or faces of one or more layers of the spacertextile material. However, the ends of each tensile strand may befinished in any suitable manner. For example, in some embodiments, thetensile strand ends may extend beyond the edge of the spacer material.In such an embodiment, the ends of the tensile strand may extend into asecond material or structure. Further, the ends of the tensile strandmay be knotted or tied off so that the ends may not recess into thespacer textile material. Further, the ends may extend into the spacertextile material in a second direction and continue to extend throughoutthe material in a selected manner or pattern. In other embodiments, theends of the tensile strand may be flush with the edge of the spacertextile material. Still further, the end of the tensile strand may bejoined to the edge of one or more layers of the spacer textile material.

In addition to a tensile strand, the spacer textile material may includeprovisions for restricting the movement of the tensile strand within thespacer textile material. In some embodiments, a spacer textile materialcan include provisions for restricting the movement of one portion ofthe tensile strand. In other embodiments, a spacer textile material caninclude provisions for restricting two or more portions of a tensilestrand (for example, two adjacent sides or ends of a tensile strand). Insome embodiments, a spacer textile material can include one or morechannels that act to restrict or restrain the movement various portionsof the tensile strand. For example, a tensile strand disposed inside achannel of a spacer textile material may move freely in a longitudinaldirection of the channel, while motion of the tensile strand in thelateral direction of the channel may be restricted.

For instance, FIG. 5, which is discussed below is further detail,depicts spacer textile material 500 having portions of a tensile stranddisposed within spacer textile material 500. Portions of a tensilestrand may be further disposed in two channels, first channel 360 andsecond channel 362. As shown in FIG. 5, the tensile strand portions maybe restricted in the lateral direction on both sides while the tensilestrand portions are free to move within each channel in the longitudinaldirection.

The channels formed in the spacer textile material may have any width.In some embodiments the width of the channel may accommodate one tensilestrand. In other embodiments, the width of the channel may be largeenough to accommodate two or more tensile strands. In addition, a firstchannel may have one width and a second channel may have a second width.The widths of multiple channels may be the same or the widths may bedifferent. Further, the width of a single channel may change over therun of the channel. In other words, the width of the channel may varythroughout the length of the channel. For example, a channel may have awidth that increases from a first edge to a second edge of a spacertextile material.

In some embodiments, channels of a spacer textile material may bebounded by portions of the first layer and the second layer that are indirect contact. In some embodiments, sections of the first layer and thesecond layer may be joined or fused to form one or more channels. Thefirst layer may be joined to the second layer by any suitable method ofjoining such layers. In some embodiments, the first layer is joined tothe second layer through a welding method. However, in otherembodiments, the joining of the first layer and the second layer couldbe accomplished using other methods including, but not limited to:stitching, adhesives as well as other joining methods.

In some embodiments, the first layer and the second layer could bejoined in a manner that forms one or more channels for guiding andcontrolling the configuration and possible motions of a tensile strand.For example, in some embodiments one or more welds could be used to jointhe first layer and the second layer such that adjacent welds form thewalls of one or more channels.

In some embodiments, welding methods may be utilized to join the firstlayer to the second layer. The welding method utilized to join the firstlayer to the second layer may include a high frequency welding method.In some embodiments, the high frequency welding method may include anultrasonic welding method or a radio frequency welding method.

In those embodiments that include ultrasonic welding methods, anultrasonic welding device is used to join the first layer to the secondlayer of the spacer textile material. Ultrasonic welding devices utilizehigh frequency ultrasonic acoustic vibrations. The vibrations may beapplied locally to a portion of the spacer textile material. Further,the vibrations applied to the spacer textile material cause friction.The friction softens the spacer textile material to fuse the first layerto the second layer. The fusion of the first layer to the second layermay be considered a solid state weld.

Examples of ultrasonic techniques and equipment are disclosed in any ofthe following: Albanese et al., U.S. Pat. No. 7,883,594, entitled“Wrapped pile weatherstripping and methods of making same,” issued onFeb. 8, 2011; Chernyak, U.S. Pat. No. 7,824,513, entitled “Apparatus andmethod for making pile articles and improved pile articles madetherewith,” issued on Nov. 2, 2010; Lehto et al., U.S. Pat. No.7,776,171, entitled “Arrangement and method for treatment of a materialby means of an ultrasonic device,” issued on Aug. 17, 2010; Perrine,U.S. Pat. No. 6,835,257, entitled “Ultrasonic weld pattern for adsorbentcontaining package” issued on Dec. 28, 2004; and Collette et al., U.S.Pat. No. 5,713,399, entitled “Ultrasonic seaming of abutting strips forpaper machine clothing” issued on Feb. 3, 1998; the entirety of eachbeing hereby incorporated by reference. One or more of the principles,concepts or methods disclosed in the cited references above may beimplemented for preparing the welds on the spacer textile material ofthis disclosure.

FIG. 3 shows an embodiment of spacer textile material 300 in a weldingdevice. Spacer textile material 300 may include first layer 310, secondlayer 320 and connecting members 330. Spacer textile material 300 mayfurther include a tensile strand 340 with first end 342 and second end344. Tensile strand 340 may be located between first layer 310 andsecond layer 320.

In order to fuse portions of first layer 310 and second layer 320together, spacer textile material 300 having tensile strand 340 may bepositioned between a horn 350 and an anvil 360 of the welding device. Asseen in FIG. 3, horn 350 may have a one or more protrusions. In someembodiments, horn 350 may have first protrusion 351, second protrusion353, and third protrusion 355.

Each protrusion may form a pattern that is to be welded into the spacertextile material. The protrusions may form any suitable pattern. Thepatterns formed by one or more protrusions may include a stripe or line,parallel stripes or lines, perpendicular stripes or lines, a zig-zagpattern, a triangular pattern, and a wavy pattern, among other patterns.

For purposes of illustration, horn 350 and anvil 360 are shownschematically in the embodiments. Generally, the anvil 360 is a fixedcomponent where the material to be welded rests or is nested. The horn350 may be a sonotrode, which is connected to a transducer (not shown).The transducer causes the horn 350 to resonate or emit an acousticvibration. In some embodiments, the frequency at which a horn vibratesmay be between about 15 kHz and 85 kHz. Some examples of typicalfrequencies at which a horn vibrates include 15 kHz, 20 kHz, 30 kHz, 35kHz, 40 kHz, and 70 kHz. The frequency chosen may depend on the materialbeing welded as well as possibly other factors.

Horn 350 and anvil 360 come together under pressure to join a firstmaterial to a second material. In the embodiments shown in FIGS. 3 and4, a first layer 310 is joined to a second layer 320 of spacer textilematerial 300. First layer 310 may be joined to second layer 320 in thelocation in which the material comes in contact with one or more of theprotrusions, including first protrusion 351, second protrusion 353, andthird protrusion 355, of horn 350.

FIG. 4 provides a schematic of an embodiment of an ultrasonic weldingmethod. In FIG. 4, first protrusion 351, second protrusion 353 and thirdprotrusion 355 of horn 350 cause first layer 310 to meet second layer320 at first weld 348, second weld 352 and third weld 354. Thetransducer may be activated to cause horn 350 to resonate at a selectedfrequency. The vibrations of horn 350 generate friction between firstlayer 310 and second layer 320 of spacer textile material 300 and horn350. The friction causes the materials of first layer 310 and secondlayer 320 to soften or melt. First layer 310 and second layer 320 may beallowed to cool to cause the layers to fuse to each other. Followingthis joining process, first layer 310 and second layer 320 may be fusedor welded in those areas contacted by horn 350.

FIG. 5 depicts an embodiment of the welded spacer textile material 500.As can be seen, first weld 348, second weld 352 and third weld 354 maybe generated by a welding device, as shown in FIG. 4. At each weld,first layer 310 may be fused to second layer 320. Further, first weld348, second weld 352, and third weld 354 define two channels, firstchannel 360 and second channel 362. Both channels include portions oftensile strand 340. Tensile strand 340 is free to move in a longitudinaldirection within the channels. However, the welds on both sides oftensile strand 340 restrain the lateral movement of tensile strand 340within each channel of the spacer textile material 500.

In some embodiments, the welded spacer textile material, or a portion ofthe welded spacer textile material, may be incorporated into footwear,for example, as shown in FIG. 14, discussed below in further detail. Insome cases, the spacer textile material may be configured for use in awide range of athletic footwear styles, including running shoes,basketball shoes, cross-training shoes, football shoes, golf shoes,hiking shoes and boots, ski and snowboarding boots, soccer shoes, tennisshoes, and walking shoes, for example. Concepts associated with thespacer textile material may also be utilized with footwear styles thatare generally considered to be primarily non-athletic, including dressshoes, loafers, sandals, casual shoes, clogs, flats, heels, pumps,wedges, and work boots.

In addition to footwear, the spacer textile material may be incorporatedinto other types of apparel and athletic equipment, including helmets,gloves, and protective padding for sports, such as football and hockey.Similar material may also be incorporated into cushions and othercompressible structures utilized in household goods and industrialproducts.

Additionally, the discussion and figures disclose various configurationsof a spacer textile material. Although portions of the spacer textilematerial are disclosed as being incorporated into footwear, the spacertextile material may be utilized with a variety of other products or fora variety of other purposes. In some embodiments, the spacer textilematerial may be utilized in apparel, such shirts, shorts, pants,outerwear, sports uniforms/jerseys, hats, socks, and undergarments,among other pieces of apparel.

The welding method described above is not restricted to the patternsdescribed in this disclosure. The welding device may be configured toprepare a spacer textile material with a wide variety of patterns andtextures.

The spacer textile material may be formed from any suitable material. Insome embodiments, the material used in making a spacer textile materialmay be suitable for the joining method utilized to join the first layerto the second layer of the spacer textile material.

In those embodiments where an ultrasonic welding method is utilized tojoin the first layer and second layer of the spacer textile material,the spacer textile material may be made of any material suitable forsuch a spacer textile configuration. Further, the spacer textilematerial may be made of any material suitable for high frequency weldingmethods. Materials suitable for high frequency welding includethermoplastic material or natural material coated with a thermoplasticmaterial. Examples of material suitable for high frequency weldingmethods include an acrylic, a nylon, a polyester, a polylactic acid, apolyethylene, a polypropylene, polyvinyl chloride (PVC), an urethane, anatural fiber, such as cotton or wool, that is coated with one or morethermoplastic materials, such as an ethyl vinyl acetate or thermoplasticpolyurethane, and combinations thereof.

In some embodiments, the first layer and the second layer of a spacertextile material may be made of the same material or combination ofmaterials. In other embodiments, the first layer may be made of onesuitable material or combination of materials, and the second layer maybe made of a second suitable material or combination of materials thatare different from the first layer.

Further, the connecting members of the spacer textile material may bemade of any suitable material. In some embodiments, the material of theconnecting member may be the same as the material of the first layer. Inother embodiments, the material of the connecting members may be thesame as the material of the second layer. In still further embodiments,the material of the connecting members may be substantially differentthan both the material of the first layer and the material of the secondlayer.

Other welding methods may be utilized to join layers of a spacer textilematerial. For example, in some embodiments a radio frequency (RF)welding method could be used. In some embodiments, radio frequencywelding could be used with a hot melt adhesive. In some cases, the useof a hot melt adhesive may enhance the application of RF welding to alow mass spacer textile material.

Welding methods could also be used with a variety of differentmaterials. In some embodiments, materials having desired channelgeometry can be achieved by selecting a combination of a welding methodand a suitable material or materials. For example, some embodimentscould use thermoplastic polyurethane (TPU) in combination withultrasonic welding to achieve the desired channel geometry on a portionof an upper or other section of an article.

Still other methods are possible for joining layers of a spacer textilematerial. As one example, in other embodiments, the first layer may bejoined to the second layer by a thermal fusion method. The thermalfusion method may include heat bonding. Heat bonding methods include hotdie heating, steam heating or hot air heating.

In further embodiments, the first layer may be joined to the secondlayer through stitching methods or weaving methods. In some embodiments,where the layers are joined through stitching methods, the material usedto form the stitch may be the same as the material of the first layer orsecond layer. In other embodiments, the materials used to form thestitch may be a different material from both the first layer and thesecond layer of the spacer textile material.

It will be understood that the embodiments are not limited to anyparticular method for forming channels in a spacer textile material. Inparticular, the embodiments depict various configurations of a spacertextile material that allows for tensile strands (such as wires) to becaptured and guided through various channels. Although the followingembodiments may reference welding or welds used to join regions oflayers in a spacer textile material, it should be understood that inother embodiments the regions of joined material could be created usingstitching, gluing, as well as possibly other methods.

One or more tensile strands and/or associated channels could be arrangedin a variety of configurations within a spacer textile material. Asstated above, portions of the tensile strand may enter or exit thespacer textile material at any point on the material. Further, thetensile strands, and channels in which the tensile strands are disposed,may be arranged in any pattern including, but not limited to: linearpatterns, non-linear patterns, regular patterns, irregular patterns aswell as any other patterns.

FIGS. 6 through 11 illustrate various different configurations orarrangements of one or more tensile members in a spacer textilematerial. It will be understood that the following configurations areonly intended to be exemplary and still other configurations may bepossible in other embodiments. Moreover, features of the differentembodiments may be combined to create still further arrangements for oneor more tensile strands within a spacer textile material.

Some embodiments may include tensile strands that extend throughportions of a spacer textile material in various non-linear patterns orconfigurations. The term “non-linear pattern” as used throughout thisdetailed description and in the claims may refer to a pattern fortensile strands as well as the associated channels and/or welds usedwith the tensile strands. Moreover, a non-linear pattern is any patternhaving at least one non-linear element. For example, a non-linearpattern for a tensile strand may be one in which two or more portions ofthe tensile strand are not parallel. As another example, a non-linearpattern for a tensile strand may be formed using two separate tensilestrands that are arranged in a non-parallel manner with respect to oneanother. Likewise, a non-linear pattern for a channel and/or weld may beone in which two or more channels and/or welds are not parallel.Similarly, a non-linear pattern for a channel and/or weld may be one inwhich two or more portions of a single channel and/or a single weld arenot parallel.

Non-linear patterns in tensile strands, channels and/or welds associatedwith a spacer textile material can be accomplished by forming theseelements with one or more bends, turns, arcs, curves, loops as well asby the use of possibly other provisions. For example, some embodimentsmay include a plurality of channels that are angled with respect to anedge of a spacer textile material. Other embodiments can include tensilestrands with bends, kinks and loops that cause two or more portions ofthe tensile strand to be non-parallel.

For purposes of clarity, the term “plurality of channels” as usedthroughout this detailed description and in the claims refers to anygroup of two or more channels. Likewise, the term “plurality of welds”as used throughout this detailed description and in the claims refers toany group of two or more welds.

FIG. 6 is an embodiment in which multiple portions of the tensile strandextend from and through the spacer textile material in a generallynon-linear pattern or configuration. A spacer textile material mayinclude provisions for controlling the orientation of a tensile strand,which may allow the direction of the tension to be better controlledthrough a portion of a material, such as a shoe upper. In addition, thetensile strand may be disposed above the face of a layer of the spacertextile material. In some embodiments, when the tensile strand may bedisposed above the face of a layer of a spacer textile material, thetensile strand may interact with other features of an article offootwear, such the laces.

The embodiment depicted in FIG. 6 includes a tensile strand that extendsfrom the spacer textile material along an edge as well as through theface of one layer. More specifically, portions of tensile strand 640 maybe disposed between first layer 610 and second layer 620 of a spacertextile material 600. Further, spacer textile material 600 may include aplurality of connecting members 630 that extend between and join firstlayer 610 and second layer 620. Spacer textile material 600 of FIG. 6also may have four edges, including first edge 680, second edge 682,third edge 684 and fourth edge 686, which are also edges of first layer610 and second layer 620.

In some embodiments, portions of spacer textile material 600 may bewelded together using methods such as those described above. Spacertextile material 600 may include a plurality of welds that includesfirst weld 650, second weld 652, third weld 654, and fourth weld 657.First weld 650, second weld 652, third weld 654, and fourth weld 657form two channels, first channel 660 and second channel 662, in thespacer textile material. For purposes of reference, first channel 660and second channel 662 may be collectively referred to as a plurality ofchannels.

In this embodiment, first channel 660 and second channel 662, along withfirst weld 650, second weld 652, third weld 654 and fourth weld 657, arearranged in a generally non-linear pattern. In particular, first channel660 extends from first edge 680 at a first angle 671, while secondchannel 662 extends from first edge 680 at a second angle 673. In someembodiments, first angle 671 is substantially greater than second angle673. Moreover, this difference in orientation relative to first edge 680means that first channel 660 and second channel 662 are generally notparallel to one another. In other words, first channel 660 and secondchannel 662 (as well as their associated welds) are arranged in anon-linear pattern on spacer textile material 600.

The non-linear pattern for the plurality of channels comprised of firstchannel 660 and second channel 662 results in a generally non-linearpattern for tensile strand 640 as tensile strand 640 is constrained tomove through first channel 660 and second channel 662. In FIG. 6, firstportion 646 of tensile strand 640 may be disposed between first layer610 and second layer 612 of spacer textile material 600. In addition,first portion 646 may be disposed in first channel 660, which extends tofirst opening 647. First opening 647 may be located on the face, orouter surface, of first layer 610. Tensile strand 640 may extend fromspacer textile material 600 through first opening 647.

A second portion 656 of tensile strand 640 may extend from first opening647 to second opening 648 and may be disposed outside of the spacertextile material 600. In some embodiments, second portion 656 forms aloop above the face of first layer 610. A third portion 649 of tensilestrand 640 may be disposed in second channel 662 in spacer textilematerial 600 from second opening 648 to first edge 680.

Because first portion 646 of tensile strand 640 and third portion 649 oftensile strand 640 extend through non-parallel channels (first channel660 and second channel 662), first portion 650 and third portion 649 arelikewise oriented in non-parallel directions. In particular, firstportion 650 may be oriented at an approximate angle 693 with respect tofirst edge 680, while third portion 649 may be oriented at anapproximate angle 695 with respect to first edge 680. In someembodiments, angle 693 and angle 695 may be approximately differentangles such that first portion 646 and third portion 649 arenon-parallel.

Additionally, as second portion 656 forms a loop-like portion havingnon-zero curvature 697, second portion 656 is seen to have a non-linearshape. Moreover, second portion 656 is non-parallel with first portion650 and third portion 649.

By arranging first channel 660 and second channel 662 as well as tensilestrand 640 in non-linear patterns or configurations, the tension appliedto spacer textile material 600 by tensile strand 640 can be oriented ina variety of different directions. Moreover, using a plurality ofchannels arranged in generally non-linear patterns may allow forsmoother travel of tensile strand 640 through the channels by avoidingsharp turns and/or kinks that may otherwise develop in configurationswhere a tensile strand exits one channel and enters an adjacent channelthat is parallel to original channel.

The embodiments described throughout the detailed descriptioncharacterize the orientations of one or more channels (or tensile strandportions) relative to an edge of the spacer textile material. However,the orientations could also be characterized using angles relative toany other portion of the spacer textile material. For example, anglesmeasured relative to any approximately straight feature (an edge of thespacer textile material, an edge of a sole, a stitch, as well as otherapproximately straight features) that intersects two or more channels,welds or tensile strands may be substantially different for any twonon-parallel channels, welds or tensile strands.

FIG. 7 depicts another embodiment in which a plurality of channelsformed in a spacer textile material are positioned in a non-linearconfiguration. As shown in FIG. 7, a tensile strand 740 may be disposedbetween first layer 710 and second layer 720 of a spacer textilematerial 700. Further, spacer textile material 700 may include aplurality of connecting members 730 that extend between and join firstlayer 710 and second layer 720. Spacer textile material 700 also mayhave four edges, including first edge 780, second edge 782, third edge784 and fourth edge 786, which are also edges of first layer 710 andsecond layer 720. Portions of tensile strand 740 may be disposed betweenfirst layer 710 and second layer 720 and in the space created betweenconnecting members 730.

Spacer textile material 700 may further include a first channel 760,formed by first weld 750 and second weld 752, and a second channel 762,formed by third weld 754 and fourth weld 756, respectively. In thisembodiment, first channel 760 and second channel 762 may be oriented innon-parallel directions. In particular, first channel 760 may generallyform an angle 790 with first edge 780, while second channel 762 maygenerally form an angle 792 with first edge 780. In some embodiments,angle 790 may be approximately a right angle, such that first channel760 generally extends in a perpendicular manner from first edge 780. Insome embodiments, angle 792 may generally be an acute angle that issubstantially less than 90 degrees.

This generally non-linear arrangement for first channel 760 and secondchannel 762 may result in a non-linear arrangement for tensile member740, which extends through first channel 760 and second channel 762. Inparticular, a first portion 745 of tensile member 740 may run generallyparallel with first channel 760, while a third portion 747 of tensilemember 740 may run generally parallel with second channel 762. Sincefirst channel 760 and second channel 762 are generally non-parallel,this configuration results in first portion 745 and third portion 747 oftensile member 740 also being generally non-parallel with one another.Moreover, second portion 746 of tensile member 740 is a curved portionthat forms a loop extending between first channel 760 and second channel762 along third edge 784.

FIG. 8 illustrates an embodiment that may have three channels throughwhich the tensile strand maybe disposed, none of which are parallel toeach other. Similar to the embodiments described above, portions of atensile strand 840 may be disposed between first layer 810 and secondlayer 820 of a spacer textile material 800. Further, spacer textilematerial 800 may include a plurality of connecting members 830 thatextend between and join first layer 810 and second layer 820. Spacertextile material 800 also may have four edges, including first edge 880,second edge 882, third edge 884 and fourth edge 886, which are alsoedges of first layer 810 and second layer 820.

Spacer textile material 800 may include at least three channels. Inparticular, spacer textile material 800 may include first channel 860(formed by first weld 850 and second weld 852), second channel 862(formed by second weld 852 and third weld 854) and third channel 864(formed by fourth weld 856 and fifth weld 858). Moreover, tensile member840 may extend through each of first channel 860, second channel 862 andthird channel 864. In particular, first portion 870, second portion 872and third portion 874 of tensile member 840 may extend through firstchannel 860, second channel 862 and third channel 864, respectively.Additionally, a fourth portion 844 of tensile member 840 may extendbetween first channel 860 and second channel 862, while a fifth portion846 of tensile member 840 may extend between second channel 862 andthird channel 864.

In some embodiments, each of first channel 860, second channel 862 andthird channel 864 may be oriented so that no two channels are parallelwith one another. In particular, first channel 860 may be oriented at anangle 890 with respect to first edge 880 of spacer textile material 800.Second channel 862 may be oriented at an angle 892 with respect to firstedge 880. Also, third channel 864 may be oriented at an angle 894 withrespect to first edge 880. As seen in FIG. 8, angle 890, angle 892 andangle 894 may be substantially different angles. For example, angle 890may be approximately 90 degrees, while angle 892 and angle 894 may besubstantially greater than 90 degrees. Furthermore, angle 892 may bedifferent than angle 894, for example, an angle between 90 degrees andthe value of angle 894.

The configuration depicted in FIG. 8 allows the direction of the tensionto be selectively tuned by varying the orientation of each channeldisposed about the spacer textile material in a non-linear manner.

FIG. 9 illustrates an embodiment of a spacer textile material thatincludes four channels through which the tensile strand is disposed. Insome embodiments, none of the four channels are parallel to each other.Similar to the embodiments described above, a tensile strand 940 may bedisposed between first layer 910 and second layer 920 of a spacertextile material 900. Further, spacer textile material 900 may include aplurality of connecting members 930 that extend between and join firstlayer 910 and second layer 920. Spacer textile material 900 also mayhave four edges, first edge 980, second edge 982, third edge 984 andfourth edge 986, which are also edges of first layer 910 and secondlayer 920.

Spacer textile material 900 may include at least three channels. Inparticular, spacer textile material 900 may include first channel 960(formed by first weld 950 and second weld 952), second channel 962(formed by third weld 954 and fourth weld 955), third channel 964(formed by fifth weld 956 and sixth weld 957) and fourth channel 966(formed by seventh weld 958 and eighth weld 959). Moreover, tensilemember 940 may extend through each of first channel 960, second channel962, third channel 964 and fourth channel 966. In particular, firstportion 943, second portion 945, third portion 947 and fourth portion951 of tensile member 940 may extend through first channel 960, secondchannel 962, third channel 964 and fourth channel 966, respectively.Additionally, a fifth portion 944 of tensile member 940 may extendbetween first channel 960 and second channel 962. Also, a sixth portion946 of tensile member 940 may extend between second channel 962 andthird channel 964. Finally, a seventh portion 948 of tensile member 940may extend between third channel 964 and fourth channel 966.

As discussed above, first channel 960, second channel 962, third channel964 and fourth channel 966 may generally form a non-linear pattern onspacer textile material 900. In some embodiments, first channel 960 andsecond channel 962 are positioned in non-linear directions relative toeach other. Further, second channel 962 and third channel 964 arepositioned in non-linear directions relative to each other. Further,third channel 964 and fourth channel 966 are positioned in non-lineardirections relative to each other. In other words, in some embodiments,the four channels are not parallel.

The channels of spacer textile material 900 may be disposed about spacertextile material 900 at different angles. For example, first channel 960may extend from first edge 980 to opposite third edge 984 at any firstangle 990 relative to first edge 980. Further, second channel 962 mayextend from first edge 980 to opposite third edge 984 at any secondangle 992 relative to first edge 980. Still further, third channel 964may extend from first edge 980 to opposite third edge 984 at any thirdangle 994 relative to first edge 980. In addition, fourth channel 966may extend from third edge 984 to fourth edge 986 at any fourth angle996 relative to third edge 984. In some embodiments, first angle 990,second angle 992, third angle 994, and fourth angle 996 aresubstantially different from one another.

The configuration depicted in FIG. 9 allows the direction of the tensionto be selectively tuned by varying the position of each channel. Thechannels of the embodiment shown in FIG. 9 are positioned in anon-linear manner in spacer textile material 900.

Some embodiments may include sets of channels that functionindependently to apply tension selectively throughout a spacer textilematerial. In some embodiments, such sets of channels (and correspondingtensile strands) could be arranged in various non-linear patterns.

FIG. 10 depicts an embodiment where at least two strands may be disposedwithin or about the spacer textile material in a non-linear ornon-parallel pattern. Each tensile strand may function substantiallyindependently from other tensile strands. Therefore, the tension of eachtensile strand may be selectively tuned for the location of the tensilestrand on or about the spacer textile material.

As previously discussed, some embodiments include configurations inwhich tensile strands are disposed both between layers as well as alongan outer face of at least one layer. As shown in FIG. 10, portions offirst tensile strand 1040 may be disposed between first layer 1010 andsecond layer 1020 of spacer textile material 1000. In addition, portionsof first tensile strand 1040 may be disposed externally above the faceof a layer of spacer textile material 1000. Further, portions of secondtensile strand 1050 may be disposed between first layer 1010 and secondlayer 1020 of spacer textile material 1000. Still further, portions ofsecond tensile strand 1050 may be disposed externally above the face ofa layer of spacer textile material 1000.

Spacer textile material 1000 of FIG. 10 may include a plurality ofconnecting members 1030 that extend between and join first layer 1010and second layer 1020. Spacer textile material 1000 of FIG. 10 also mayhave four edges, including first edge 1080, second edge 1082, third edge1084 and fourth edge 1086, which are also edges of first layer 1010 andsecond layer 1020.

Spacer textile material 1000 may further include a first channel 1061,formed by first weld 1060 and second weld 1062, and a second channel1063, formed by third weld 1064 and fourth weld 1066. In thisembodiment, first channel 1061 and second channel 1063 may be orientedin non-parallel directions. In particular, first channel 1061 maygenerally form an angle 1090 with first edge 1080, while second channel1063 may generally form an angle 1092 with first edge 1080. In someembodiments, angle 1090 and angle 1092 may be substantially differentsuch that first channel 1061 and second channel 1063 are generallynon-parallel.

Spacer textile material 1000 may also include a third channel 1065,formed by fifth weld 1070 and sixth weld 1072, and a fourth channel1067, formed by seventh weld 1074 and an eighth weld 1076. In thisembodiment, third channel 1065 and fourth channel 1067 may be orientedin non-parallel directions. In particular, third channel 1065 maygenerally form an angle 1094 with third edge 1084, while fourth channel1067 may generally form an angle 1096 with third edge 1084. In someembodiments, angle 1094 and angle 1096 may be substantially differentsuch that third channel 1065 and fourth channel 1067 are generallynon-parallel.

In this embodiment, first channel 1061 and second channel 1063 maygenerally be associated with a first tensile member 1040 while thirdchannel 1065 and fourth channel 1067 may generally be associated with asecond tensile member 1050, which may be a distinct tensile member fromfirst tensile member 1040. In particular, first tensile member 1040includes first portion 1043 and third portion 1045 which extend throughfirst channel 1061 and second channel 1063, respectively. Additionally,a second portion 1046 of tensile member 1040 extends from first opening1047 and second opening 1048 such that second portion 1046 is exposedalong the outer surface of spacer textile material 1000. Additionally,second tensile member 1050 includes first portion 1053 and third portion1055 which extend through third channel 1065 and fourth channel 1067,respectively. Additionally, a second portion 1056 of tensile member 1050extends from third opening 1057 and fourth opening 1058 such that secondportion 1056 is exposed along the outer surface of spacer textilematerial 1000.

This particular configuration provides a non-linear pattern for firstchannel 1061, second channel 1063, third channel 1065 and fourth channel1067. Moreover, these non-linear channel arrangements provide non-lineararrangements for first tensile member 1040 and second tensile member1050, which are configured to apply tension to spacer textile material1000 independently of one another.

As show in FIG. 10, more than one tensile strand may be disposed betweenthe first layer and second layer of a spacer textile material in anon-linear manner. By positioning each tensile strand in specificnon-linear locations, the tension in each location may be selectivelytuned with each tensile strand independent of the other tensile strands.

The above described spacer textile material may be incorporated into atleast a portion of an article of footwear. The spacer textile materialmay be incorporated into at least a portion of a shoe upper. In someembodiments, the spacer textile material is the shoe upper.

When incorporated into a shoe upper, the spacer textile material mayhave any number of tensile strands. The tensile strands of the spacertextile material incorporated into a shoe upper may be disposed in thespacer textile material in any location within or about the spacertextile material. An embodiment, as shown in FIG. 11, incorporatesmultiple tensile strands into a spacer textile material. In addition,the tensile strands are located in the spacer textile material in anon-linear pattern.

The tensile strands shown in article of footwear 1100 depicted in FIG.11 may be disposed in spacer textile material 1110 incorporated intoshoe upper 1112. As shown in FIG. 11, spacer textile material 1110 mayinclude multiple welds that define multiple channels. More specifically,first weld 1122 and second weld 1124 define first channel 1130.Similarly, third weld 1126 and fourth weld 1128 define second channel1132. First portion 1142 of tensile strand 1140 may be disposed in firstchannel 1130. Further, first portion 1142 may extend from sole structure1120 within first channel 1130 to first opening 1160 disposed on theouter face of the outer layer of spacer textile material 1110. Tensilestrand 1140 may extend from spacer textile material 1110 through firstopening 1160. Second portion 1143 of tensile strand 1140 may form a loopon the exterior of spacer textile material 1110. Second portion 1143 maybe disposed between first opening 1160 and second opening 1162.

Third portion 1144 of tensile strand 1140 may be further disposed in thespacer textile material through second opening 1162. Third portion 1144may extend from second opening 1162 within second channel 1132 to solestructure 1120.

Portions of each tensile strand may further be similarly disposed in thespacer textile material and through the remaining channels. The channelsof spacer textile material 1110 may be positioned in a non-linearmanner. In some embodiments, none of the angles of the channels,relative to the sole structure, are the same.

As shown in FIG. 11, a portion of each tensile strand may remain outsideof the spacer textile material between the two openings on the outerface of the outer layer of the spacer textile material. This exposedportion of the tensile strand may be a loop that may be utilized as ashoe lace eyelet. Through the multiple loops in the shoe upper of FIG.11, a shoe lace may be disposed.

More specifically, second portion 1143 of tensile strand 1140 forms aloop on the exterior of spacer textile material 1110. The loop, orsecond portion 1143, may be disposed between first opening 1160 andsecond opening 1162. The loop, or second portion 1143, may also act asan eyelet to receive the shoe lace 1150.

When shoe lace 1150 is tightened, tensile strand 1140 is also tightened,or in other words, placed under an increased tension. The tightenedtensile strand 1140 provides both better support and a better fit forthe wearer of the shoe in the particular area that tensile strand 1140is disposed about spacer textile material 1110, among otherimprovements. Therefore, the wearer of the shoe may tighten shoe lace1150 to customize the fit of upper 1112 of shoe 1100.

In addition, in some embodiments, each tensile strand may have the samestretch and flexibility. In other embodiments, each tensile strand mayhave different flexibility or stretch. Accordingly, a tensile strand maybe selectively disposed in or about the spacer textile material inspecific locations to provide specific support. For instance, a tensilestrand having less flexibility or stretch may be located in or about thespacer textile material of the shoe upper in an area that requires moresupport. Further, a tensile strand having greater flexibility or stretchmay be located in or about the spacer textile material of the shoe upperin an area that requires more flex and stretch during use. Therefore, ashoe upper may include multiple tensile strands with varying degrees ofstretch and flex. The stretch and flex of each tensile strand willdepend on its location on a particular shoe upper.

While FIG. 11 depicts an article of footwear comprising a shoe upperhaving a spacer textile material that includes multiple tensile strands,the disclosure is not limited to the particular pattern depicted in FIG.11. Any of the various patterns or any combination of patterns describedabove may be incorporated into a similar article of footwear as well aspossibly other articles and other kinds of apparel.

During activities that involve walking, running, or other ambulatorymovements (e.g., cutting, braking), a foot within the shoes describedabove may tend to stretch the upper component of the shoe. That is, manyof the material elements forming the upper (e.g., spacer textilematerial layers) may stretch when placed in tension by movements of thefoot. Although the tensile strands or individual segments of the tensilestrands may also stretch, the tensile strand generally stretches to alesser degree than the other material elements forming the upper. Thevarious segments of the tensile strands may be located, therefore, toform structural components in the upper that (a) resist stretching inspecific directions or locations, (b) limit excess movement of the footrelative to the sole structure and the upper, (c) ensure that the footremains properly positioned relative to the sole structure and theupper, and (d) reinforce locations where forces are concentrated.

In addition, the welds forming the channels of the spacer textilematerial may also form structural components in the upper. The welds, afusion of the first layer to the second layer of the spacer textilematerial, may also assist the upper to (a) resist stretching in specificdirections or locations, (b) limit excess movement of the foot relativeto the sole structure and the upper, (c) ensure that the foot remainsproperly positioned relative to the sole structure and the upper, and(d) reinforce locations where forces are concentrated.

In addition to above advantages, the tensile strands also may extend atleast partially around lace apertures or act as lace aperturesthemselves. As such, a tensile strand may extend (a) upward from lowerregion of the upper or from the sole structure to a lace region, (b)exit and be disposed in the spacer textile materials forming a loop inthe lace region, and (c) travel downward from lace region to the lowerregion of the upper or the sole structure. In this manner, the loopsformed from the tensile strands effectively are lace apertures. A shoelace may be laced through the tensile strand loops. When the lace istightened, tension in the lace effectively places the tensile strands intension, which has the advantage of tightening the upper around the footand further (a) limiting excess movement of the foot relative to thesole structure and the upper, and (b) ensuring that the foot remainsproperly positioned relative to the sole structure and the upper.

Based upon the above discussion, each of spacer textile material havingtensile strands may have various configurations. Although each of theseconfigurations are discussed separately, many of the concepts presentedabove may be combined to impart specific properties or otherwise ensurethat spacer textile material having tensile strands are optimized for aparticular purpose or product.

In still other embodiments, a spacer textile material including tensilestrands arranged in various configurations may incorporated into variouskinds of articles including, but are not limited to: hiking boots,soccer shoes, football shoes, sneakers, running shoes, cross-trainingshoes, rugby shoes, basketball shoes, baseball shoes as well as otherkinds of shoes. Moreover, in some embodiments, a spacer textile materialmay be incorporated into various kinds of non-sports related footwear,including, but not limited to: slippers, sandals, high heeled footwear,loafers as well as any other kinds of footwear.

The spacer textile material could also be incorporated into variouskinds of articles of apparel and/or sporting equipment (e.g., gloves,helmets, etc.). In some embodiments, the article may include one or morearticulated portions that are configured to move. In other cases, thearticle may be configured to conform to portions of a wearer in athree-dimensional manner. Examples of articles that are configured to beworn include, but are not limited to: footwear, gloves, shirts, pants,socks, scarves, hats, jackets, as well as other articles. Other examplesof articles include, but are not limited to: protective equipment suchas shin guards, knee pads, elbow pads, shoulder pads, as well as anyother type of protective equipment. Additionally, in some embodiments,the article could be another type of article including, but not limitedto: bags, purses, backpacks, as well as other articles that may or maynot be worn.

While various embodiments of the have been described, the description isintended to be exemplary, rather than limiting and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Accordingly, embodiments are not to be restricted except inlight of the attached claims and their equivalents. Also, variousmodifications and changes may be made within the scope of the attachedclaims.

What is claimed is:
 1. A spacer textile material comprising: a firstlayer; a second layer; a plurality of connecting members extendingbetween and joining the first layer and the second layer; a tensilestrand; wherein the first layer is joined to the second layer to definea plurality of channels arranged in a non-linear pattern; wherein thetensile strand extends through the plurality of channels; wherein theplurality of channels includes a first channel that is oriented at afirst angle relative to a first edge of the spacer textile material;wherein the plurality of channels includes a second channel that isoriented at a second angle relative to the first edge of the spacertextile material; wherein the plurality of channels includes a thirdchannel that is oriented at a third angle relative to the first edge ofthe spacer textile material; wherein the plurality of channels includesa fourth channel that is oriented at a fourth angle relative to a secondedge of the spacer textile material, the second edge is opposite thefirst edge; wherein the first angle and the second angle are different;a first portion of the tensile strand extends from the second edge ofthe spacer textile material between the first channel and the secondchannel; a second portion of the tensile strand extends from the firstedge of the spacer textile material between the second channel and thethird channel; a third portion of the tensile strand extends from thesecond edge of the spacer textile material between the third channel andthe fourth channel; and a fourth portion of the tensile strand extendsfrom a third edge of the spacer textile material.
 2. The spacer textilematerial according to claim 1, wherein the second angle and the thirdangle are different.
 3. The spacer textile material according to claim2, wherein none of the first angle, the second angle, the third angleand the fourth angle are the same.
 4. The spacer textile materialaccording to claim 1, wherein the third edge of the spacer textilematerial is beside the first edge of the spacer textile material and thesecond edge of the spacer textile material.
 5. The spacer textilematerial according to claim 1, wherein no adjacent channels are parallelto each other.
 6. A spacer textile material comprising: a first layer; asecond layer; a plurality of connecting members extending between andjoining the first layer and the second layer; a first tensile strand; asecond tensile strand; wherein the first layer is joined to the secondlayer to define a plurality of channels arranged in a non-linearpattern; wherein the plurality of channels includes a first channel thatis oriented at a first angle relative to a first edge of the spacertextile material; wherein the plurality of channels includes a secondchannel that is oriented at a second angle relative to the first edge ofthe spacer textile material; wherein the plurality of channels includesa third channel that is oriented at a third angle relative to a secondedge of the spacer textile material, the second edge is opposite thefirst edge; wherein the plurality of channels includes a fourth channelthat is oriented at a fourth angle relative to the second edge of thespacer textile material; wherein the first angle and the second angleare different; a first portion of the first tensile strand is disposedwithin the first channel and a second portion of the first tensilestrand is disposed within the second channel; wherein a third portion ofthe first tensile strand extends along an outer surface of the firstlayer; a first portion of the second tensile strand is disposed withinthe third channel and a second portion of the second tensile strand isdisposed within the fourth channel; and wherein a third portion of thesecond tensile strand extends along an outer surface of the first layer.7. The spacer textile material according to claim 6, wherein the thirdportion of the first tensile strand extends through the outer surface ofthe first layer at a first opening, forms a loop above the outer surfaceand enters the outer surface at a second opening.
 8. The spacer textilematerial according to claim 7, wherein the third portion of the secondtensile strand extends through the outer surface of the first layer at athird opening, forms a loop above the outer surface and enters the outersurface at a fourth opening.
 9. The spacer textile material according toclaim 6, wherein the third angle and the fourth angle are different. 10.The spacer textile material according to claim 6, wherein none of thefirst angle, the second angle, the third angle and the fourth angle arethe same.
 11. The spacer textile material according to claim 6, whereinno adjacent channels are parallel to each other.
 12. An article offootwear comprising: an upper and a sole structure, wherein at least aportion of the upper comprises a spacer textile material comprising: afirst layer; a second layer; a plurality of connecting members extendingbetween and joining the first layer and the second layer; a tensilestrand; a plurality of edges; wherein the first layer is joined to thesecond layer along a plurality of welds and wherein the plurality ofwelds define a plurality of channels arranged in a non-linear pattern;wherein the tensile strand extends through the plurality of channels;wherein a first portion of the tensile strand and a third portion of thetensile strand extend from a first edge of the plurality of edges;wherein a second portion of the tensile strand extends from a secondedge of the plurality of edges, the second edge is opposite the firstedge; and wherein a fourth portion of the tensile strand extends from athird edge of the plurality of edges, the third edge is beside the firstedge and the second edge.
 13. The article of footwear according to claim12, wherein the plurality of channels includes a first channel, a secondchannel, a third channel and a fourth channel, wherein each channel isoriented in a non-parallel direction from another channel.
 14. Thearticle of footwear according to claim 13, wherein the first channel ispositioned at first angle relative to the sole structure; the secondchannel is positioned at a second angle relative to the sole structure;the third channel is positioned at a third angle relative to the solestructure; and wherein the first angle, the second angle and the thirdangle are different from each other.
 15. The article of footwearaccording to claim 14, wherein: the first portion of the tensile strandforms a first loop between the first channel and the second channel; thesecond portion of the tensile strand forms a second loop between thesecond channel and the third channel; the third portion of the tensilestrand forms a third loop between the third channel and the fourthchannel; and the fourth portion of the tensile strand extends from thefourth channel.
 16. The article of footwear according to claim 15,wherein a lace of the upper is inserted through the first loop formed bythe first portion and through the third loop formed by the third portionsuch that tensioning the lace tensions the tensile strand.
 17. Thearticle of footwear according to claim 12, wherein the plurality ofchannels are disposed on a side of the upper.
 18. An article of footwearcomprising: an upper, wherein at least a portion of the upper comprisesa spacer textile material; the spacer textile material including a firstlayer, a second layer, a plurality of connecting members extendingbetween and joining the first layer and the second layer, a firsttensile strand, and a second tensile strand; wherein portions of thefirst layer and the second layer are in direct contact to define aplurality of channels arranged in a non-linear pattern; wherein thefirst tensile strand extends through a first channel of the plurality ofchannels and a second channel of the plurality of channels; wherein thefirst channel is oriented at a first angle relative to a first edge ofthe spacer textile material; wherein the second channel is oriented at asecond angle relative to the first edge of the spacer textile material;wherein the second tensile strand extends through a third channel of theplurality of channels and a fourth channel of the plurality of channels;wherein the third channel is oriented at a third angle relative to asecond edge of the spacer textile material, the second edge is oppositethe first edge; wherein the fourth channel is oriented at a fourth anglerelative to the second edge of the spacer textile material; wherein aportion of the first tensile strand extends along an outer surface ofthe spacer textile material; and wherein a portion of the second tensilestrand extends along an outer surface of the spacer textile material.19. The article of footwear according to claim 18, wherein the portionof the first tensile strand extends through the outer surface of thespacer textile material at a first opening, forms a loop above the outersurface and enters the outer surface at a second opening.
 20. Thearticle of footwear according to claim 19, wherein the portion of thesecond tensile strand extends through the outer surface of the spacertextile material at a third opening, forms a loop above the outersurface and enters the outer surface at a fourth opening.
 21. Thearticle of footwear according to claim 20, wherein a lace of the upperis inserted through the loop of the first tensile strand and through theloop of the second tensile strand such that tensioning the lace tensionsthe tensile strand.
 22. The article of footwear according to claim 18,wherein the portions of the first layer and the second layer that are indirect contact are welds.
 23. The article of footwear according to claim18, wherein none of the first angle, the second angle, the third angleand the fourth angle are the same.
 24. The article of footwear accordingto claim 18, wherein the plurality of channels are disposed on a side ofthe upper.